Devices and methods for monitoring water flow through a chlorine-generating or other assembly

ABSTRACT

Assemblies designed to facilitate detection of water flow in low water flow situations. In some embodiments, the assembly includes a channel that narrows from an inlet end of the assembly to an outlet end of the assembly to increase the velocity of water flowing through the channel. In some embodiments, the assembly may also include a water delivery mechanism that delivers water flowing through the channel to a flow sensor and enables the detection of water flow, even in low flow situations.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional PatentApplication No. 61/928,469 filed Jan. 17, 2014 and titled “Method ofMonitoring Flow Utilizing a Gas Trap Sensor at Low Flows,” the contentof which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to devices and methods fordetecting and/or monitoring water flow through a chlorine-generating orother assembly.

BACKGROUND

During electrolytic purification of water, a flow stream from a body ofwater is passed through an electrolytic cell or otherchlorine-generating assembly to oxide halide ions of the water byelectrolysis to form hypohalic acid, hypohalite ions or both todisinfect or “chlorinate” the water. The treated flow stream is thenreturned to the body of water.

Some assemblies for chlorinating water by electrolysis include a flowsensor that senses if water is flowing through the assembly. Such a flowsensor, sometimes referred to as a gas trap sensor, includes anelectrode that detects flow so long as there is conductivity between theelectrode and one of the chlorine-generating electrode plates of thechlorine-generating assembly. The electrolytic process generates gasbubbles that are pushed out of the assembly by the water flow. Whenwater is not flowing through the assembly, the generated gas bubblesbuild up and break the connection between the gas flow electrode and thechlorine-generating electrode plates. However, in low flow situations,for example water flowing at a rate lower than approximately 30 gallonsper minute (GPM), gas continues to build in the flow sensor faster thanthe water flow can push it out. The buildup of gas breaks the connectionbetween the gas flow electrode and the chlorine-generating electrodeplates and the flow sensor is unable to sense the water flow anderroneously returns a “no flow” condition even though water is flowingthrough the assembly.

SUMMARY

The term embodiment and like terms are intended to refer broadly to allof the subject matter of this disclosure and the claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of theclaims below. Embodiments of the present disclosure covered herein aredefined by the claims below, not this summary. This summary is ahigh-level overview of various aspects of the disclosure and introducessome of the concepts that are further described in the DetailedDescription section below. This summary is not intended to identify keyor essential features of the claimed subject matter, nor is it intendedto be used in isolation to determine the scope of the claimed subjectmatter. The subject matter should be understood by reference toappropriate portions of the entire specification of this disclosure, anyor all drawings and each claim.

Aspects of the present disclosure relate to improved chlorine-generatingassemblies and methods. More particularly, the assembly is designed insome embodiments so that a flow sensor is able to detect water flow evenin low water flow situations, for example water flowing at a rate lessthan approximately 30 GPM. In some embodiments, the assembly includes aflow channel that narrows from an inlet end of the assembly to an outletend of the assembly to increase the velocity of the water flowingthrough the flow channel. The assembly may also include a water deliverymechanism that facilitates the delivery of water through the flow sensorand thus allows the flow sensor to detect the water flow even in lowflow situations. In some embodiments, the assembly is configured so thatit can be locked and unlocked with a quarter turn. Further, in someembodiments, the assembly includes a keying feature that ensures theassembly is locked in the correct orientation.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments of the present disclosure are described indetail below with reference to the following drawing figures:

FIG. 1 is a perspective view of a chlorine-generating assembly accordingto one embodiment, shown with the upper and lower portions disassembled.

FIG. 2 is a top perspective view of the chlorine-generating assembly ofFIG. 1, shown with the upper and lower portions assembled together.

FIG. 3 is a top cut-away perspective view of select components of thechlorine-generating assembly of FIG. 1.

FIG. 4 is a partial cut-away view of the chlorine-generating assembly ofFIG. 1.

FIG. 5 is a partial cut-away schematic of the chlorine-generatingassembly of FIG. 1.

FIG. 6 is a bottom perspective view of the chlorine-generating assemblyof FIG. 1, shown with the upper and lower portions positioned withrespect to one another.

FIG. 7 a is a top view of the chlorine-generating assembly of FIG. 1,shown with the upper and lower portions assembled together and in anunlocked position.

FIG. 7 b is a top view of the chlorine-generating assembly of FIG. 1,shown with the upper and lower portions assembled together and in alocked position.

FIG. 8 is a partial cutaway view of a locking key of achlorine-generating assembly according to one embodiment.

FIG. 9 is a top perspective view of a lower portion according to oneembodiment.

FIG. 10 is a bottom perspective view of an upper portion according toone embodiment.

DETAILED DESCRIPTION

Certain aspects and features of the present disclosure relate toapparatuses and methods for sanitizing and protecting water from thegrowth of microorganisms, such as bacteria, virii, fungi, algae, and thelike. Such sanitation and protection can be used for water in a varietyof applications, including swimming pools, hot tubs, spas, as well aswastewater treatment facilities, cooling towers, and the like.

FIG. 1 illustrates one non-limiting example of a chlorine-generatingassembly 10. Chlorine-generating assembly 10 includes an upper portion12 and a lower portion 14. Chlorine-generating assembly 10 includes aflow channel 32 (FIG. 3), through which a plurality ofchlorine-generating electrode plates 24 generally extend.Chlorine-generating electrode plates 24 may be formed of any suitablematerial, including but not limited to, titanium and may be uncoated orcoated with a precious or semi-precious metal, such as platinum,ruthenium, or iridium.

The lower portion 14 includes an inlet 26, an outlet 28, and a cavity 29between inlet 26 and outlet 28. When upper portion 12 and lower portion14 are assembled together, the flow channel 32 is received within cavity29 of lower portion 14. Since upper portion 12 is removable with respectto lower portion 14, the chlorine-generating electrode plates 24 can beeasily accessed and repaired or replaced when needed. Althoughillustrated as a two-piece assembly, chlorine generating assembly mayhave any suitable configuration and is not limited to the disclosedtwo-piece arrangement.

Assembly 10 is designed so that water flows through flow channel 32, andthus across chlorine-generating electrode plates 24, in a flow direction30. As shown in FIG. 4, upper portion 12 also includes a chamber 37 thatis separated from flow channel 32 by a plate 39. A venturi tube 38 and aflow sensor 20 extend through plate 39 and are in fluid communicationwith both the chamber 37 and the flow channel 32. Flow sensor 20includes a flow sensor electrode 22. When conductivity exists in waterflowing between flow sensor electrode 22 and chlorine-generatingelectrode plates 24, the flow sensor 20 senses water flow and returns aflow condition. When the connection between the flow sensor electrode 22and the chlorine-generating electrode plates 24 is broken, the flowsensor 20 is unable to sense water flow and returns a no-flow condition,even if water is flowing through flow channel 32. The connection can bebroken, for example, when gas bubbles generated as part of thechlorine-generating electrolytic process build up in the assembly 10faster than the water flow pushes them and break the connection betweenthe flow sensor electrode 22 and the chlorine-generating electrodeplates 24. When water is flowing through the flow channel 32 at asufficient rate (in some cases, at a rate of approximately 30 GPM orabove), the venturi tube 38 evacuates air from the chamber 37 and watermoves through flow sensor 20 into chamber 37. As water moves throughflow sensor 20, the water pushes gas bubbles generated as part of theelectrolytic process out of the assembly at a faster rate than the gasbubbles are produced so that water continually covers the flow sensorelectrode 22 and a connection is maintained between the flow sensorelectrode 22 and the chlorine-generating electrode plates 24. Therefore,the flow sensor 20 senses flow and returns a flow condition.

In some embodiments, as shown in FIG. 3, the flow channel 32 narrowsfrom the inlet side 34 of the channel 32 toward the outlet side 36 ofthe channel 32. The narrowing of the flow channel 32 causes the velocityof the water to increase as it flows through the flow channel 32. Theassembly 10 also includes a water delivery mechanism 40, shown in FIG.5. As illustrated, the longitudinal axis of the water delivery mechanism40 is generally aligned with at least a portion of the flow sensorelectrode 22 of the flow sensor 20, although water delivery mechanism 40can be aligned differently.

Water delivery mechanism 40 is designed to act as a fountain that helpsdirect water flowing through flow channel 32 into contact with flowsensor electrode 22 of flow sensor 20, even in low flow situations andeven when air is present inside chamber 37. In this way, the waterdelivery mechanism 40 helps bridge any gaps between the flow sensorelectrode 22 and the chlorine-generating electrode plates 24 so that theflow sensor 20 senses water flow even in low flow situations, such asunder approximately 30 GPM or even as low as approximately 10 GPM orlower. In some embodiments, water delivery mechanism 40 includes ascooped portion 43 configured to scoop up water flowing through flowchannel 32 and direct it to flow sensor electrode 22. As illustrated,the scooped portion 43 is positioned so that water flowing through flowchannel 32 contacts the concave surface of the scooped portion 43 andtravels upward toward flow sensor electrode 22. Because the flow channel32 narrows, the water flow velocity increases and even more water ispushed across flow sensor electrode 22 via the water delivery mechanism40.

In some cases, as shown in FIGS. 1-2, upper portion 12 includes a collar15 that is rotatable with respect to a top surface 13 of the upperportion 12 and thus with respect to chlorine-generating electrode plates24. Top surface 13 may also include a viewing window 16 that is at leastpartially transparent so that at least some of the internal componentsmay be viewed when the assembly 10 is assembled. For example, in someembodiments, the lower portion 14 is opaque and the transparent viewingwindow 16 is arranged so that at least part of the top surfaces of thechlorine-generating electrode plates 24 is visible when thechlorine-generating electrode plates 24 are disposed within the opaquelower portion 14. As shown in FIGS. 1-2, a cable 18 may extend throughthe top surface 13 of the upper portion 12.

Non-limiting embodiments of assembly 10 can include various otherfeatures if desired. For example, upper portion 12 and lower portion 14can be designed to move into a locked position with a quarter-turn ofthe upper portion 12 relative to the lower portion 14, as illustrated inFIGS. 7 a-7 b. Specifically, as shown in FIG. 6, collar 15 of upperportion 12 can include two or more abutments 44 that rotatably lock withrespect to two or more flanges 42 of lower portion 14. In otherembodiments, collar 15 of upper portion 12 includes flanges 42 and lowerportion 14 includes abutments 44. As mentioned above, collar 15 isrotatable with respect to top surface 13 and chlorine-generatingelectrode plates 24. Once chlorine-generating electrode plates 24 arepositioned within lower portion 14, collar 15 can be rotated withrespect to chlorine-generating electrode plates 24 and lower portion 14to lock or unlock the assembly. Specifically, when each abutment 44 isaligned with one of the flanges 42, the upper portion 12 is locked withrespect to the lower portion 14. In some embodiments, the two abutments44 are approximately 180 degrees from one another and the two flanges 42are approximately 180 degrees from one another. To unlock the upperportion 12 with respect to the lower portion 14, one of the portions isrotated with respect to the other portion about a longitudinal axis ofthe portion until the abutments 44 are no longer aligned with the twoflanges 42. In some embodiments, the upper portion 12 is rotatedapproximately 90 degrees relative to the lower portion 14. Such a designallows the assembly 10 to be assembled into a locked position anddisassembled without requiring the use of tools. Collar 15 of upperportion 12 may also include gripping tabs 46 that facilitate locking andunlocking of the assembly.

The chlorine-generating assembly 10 described above is configured suchthat water must flow in a particular flow direction 30 to functionproperly. Therefore, it is important that the upper portion 12 beassembled correctly with respect to the lower portion 14 so that thewater flows in flow direction 30 through upper portion 12. To ensurethat the upper portion 12 (and, in turn, its water delivery mechanism 40and narrowing flow channel 32) are installed correctly, the assembly 10may include a key feature that ensures upper portion 12 is alignedcorrectly with respect to lower portion 14. If included, the key featurecan take any suitable form. One of many examples is illustrated in FIG.8. As shown in FIG. 8, cavity 29 of lower portion 14 includes a rampedsurface 50 and a recess 52. A protrusion 48 extending from the bottomsurface of upper portion 12 includes a tab 54 that is configured toslide along ramped surface 50 and be guided into recess 52. When tab 54is received within recess 52, the assembly 10 is assembled correctly andthe lower portion 14 and upper portion 12 are capable of being lockedtogether by rotating collar 15 relative to lower portion 14 as describedabove. In another non-limiting embodiment, protrusion 48 includes aplurality of slots 56 that receive a corresponding plurality of ribs 58projecting from cavity 29 of lower portion 14 when the assembly 10 isassembled correctly. When the upper portion 12 is assembled incorrectly(i.e., the water delivery mechanism 40 and flow channel 32 are notaligned correctly with respect to the lower portion 14), the ribs 58 arenot received in the slots 56 and prevent locking of the upper portion 12with the lower portion 14. These key features are illustrative only;numerous other key features may be used instead to ensure that upperportion 12 is assembled properly with respect to lower portion 14.

Although the narrowing flow channel and water delivery mechanism, whichboth facilitate detection of water flow in low flow situations, havebeen described above with respect to a chlorine-generating assembly,they can be incorporated into any suitable structure when it is desiredthat flow be sensed in low flow situations. Moreover, any or all of thedisclosed features may be used with any chlorine-generating assembly orother suitable structure and are not limited to use with the specificassembly 10 depicted and described herein.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and subcombinations are usefuland may be employed without reference to other features andsubcombinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications can be madewithout departing from the scope of the claims below.

What is claimed is:
 1. An assembly for electrolytic purification comprising: (a) an inlet and an outlet and a flow channel extending between and in fluid communication with the inlet and the outlet, (b) a plurality of chlorine-generating electrode plates disposed within the flow channel; (c) a flow sensor in fluid communication with the flow channel, wherein the flow sensor comprises a flow sensor electrode; and (d) a water delivery mechanism positioned within the flow channel and configured to alter a direction of water flowing through the flow channel so that the water is urged into contact with the flow sensor electrode.
 2. The assembly of claim 1, wherein the flow channel narrows from the inlet toward the outlet.
 3. The assembly of claim 1, wherein a longitudinal axis of the water delivery mechanism intersects at least a portion of the flow sensor electrode.
 4. The assembly of claim 1, wherein the water delivery mechanism comprises a scooped portion and wherein a concave surface of the scooped portion faces the inlet.
 5. The assembly of claim 1, wherein the assembly comprises an upper portion and a lower portion that are rotatable with respect to one another to move the assembly between an unlocked position and a locked position by rotating the upper portion relative to the lower portion.
 6. The assembly of claim 5, wherein: one of the upper portion and the lower portion comprises at least two abutments and the other of the upper portion and the lower portion comprises at least two flanges; and the assembly is in the locked position when one of the at least two abutments cooperates with one of the at least two flanges; and the assembly is in the unlocked position when the at least two abutments are not aligned with respect to the at least two flanges.
 7. The assembly of claim 6, wherein the upper portion comprises a collar that is rotatable with respect to a top surface of the upper portion.
 8. The assembly of claim 1, wherein the assembly comprises a transparent portion arranged so that at least part of a top surface of the plurality of chlorine-generating electrode plates is visible through the transparent portion when the plurality of chlorine-generating electrode plates is disposed within the flow channel.
 9. The assembly of claim 1, wherein a cable extends out of a top surface of the upper portion.
 10. The assembly of claim 1, wherein the assembly further comprises: an upper portion and a lower portion that are rotatable with respect to one another; and a keying feature that prevents the assembly from moving into a locked position when the upper portion and the lower portion are not aligned in a correct orientation.
 11. The assembly of claim 10, wherein the keying feature comprises a first feature on the upper portion and a second feature on the lower portion.
 12. The assembly of claim 11, wherein: the first feature is a tab; the second feature comprises a ramp and a recess; and the tab is configured to slide along the ramp as the assembly moves from the unlocked position towards the locked position and wherein the tab is received in the recess when the assembly is in the correct orientation.
 13. The assembly of claim 11, wherein: the first feature is a plurality of slots; the second feature is a plurality of ribs; and the plurality of ribs are received within the plurality of slots when the assembly is in the correct orientation.
 14. An assembly for electrolytic purification comprising: (a) an upper portion comprising a plurality of chlorine-generating electrode plates; (b) a lower portion comprising an inlet and an outlet and a cavity; (c) a flow channel that extends across the plurality of chlorine-generating electrode plates; wherein the upper portion is separable from the lower portion and wherein, in an assembled position, the plurality of chlorine-generating electrode plates of the upper portion is disposed in the cavity of the lower portion; and wherein, when in the assembled position, the assembly is movable between an unlocked position and a locked position by rotating the upper portion relative to the lower portion about a longitudinal axis of the assembly.
 15. The assembly of claim 14, wherein: one of the upper portion and the lower portion comprises at least two abutments and the other of the upper portion and the lower portion comprises at least two flanges; and the assembly is in the locked position when one of the at least two abutments cooperates with one of the at least two flanges; and the assembly is in the unlocked position when the at least two abutments are not aligned with respect to the at least two flanges.
 16. The assembly of claim 15, wherein the upper portion comprises a collar that is rotatable with respect to a top surface of the upper portion.
 17. The assembly of claim 14, further comprising a flow sensor with a flow sensor electrode and a water delivery mechanism positioned within the flow channel and configured to alter a direction of water flowing through the flow channel so that the water is brought into contact with the flow sensor.
 18. The assembly of claim 17, wherein a longitudinal axis containing a portion of the flow sensor electrode intersects the water delivery mechanism.
 19. The assembly of claim 17, wherein the water delivery mechanism comprises a scooped portion and wherein a concave surface of the scooped portion faces the inlet.
 20. The assembly of claim 14, wherein the flow channel narrows from the inlet toward the outlet.
 21. The assembly of claim 17, wherein the flow channel narrows from the inlet toward the outlet.
 22. An assembly for electrolytic purification comprising: (a) an upper portion comprising a plurality of chlorine-generating electrode plates; (b) a lower portion comprising an inlet and an outlet and a cavity; (c) a flow channel that extends across the plurality of chlorine-generating electrode plates; (d) a flow sensor in fluid communication with the flow channel and comprising a flow sensor electrode; and (e) a water delivery mechanism positioned within the flow channel so that a longitudinal axis of the water delivery mechanism intersects at least a portion of the flow sensor electrode, wherein the water delivery mechanism is configured to alter a direction of water flowing through the flow channel so that the water is urged into contact with the flow sensor; wherein the upper portion is separable from the lower portion and wherein, in an assembled position, the plurality of chlorine-generating electrode plates is disposed in the cavity; and wherein, when in the assembled position, the assembly is movable between an unlocked position and a locked position by rotating the upper portion relative to the lower portion about a longitudinal axis of the assembly.
 23. The assembly of claim 22, wherein the water delivery mechanism comprises a scooped portion and wherein a concave surface of the scooped portion faces the inlet.
 24. The assembly of claim 22, wherein: one of the upper portion and the lower portion comprises at least two abutments and the other of the upper portion and the lower portion comprises at least two flanges; and the assembly is in the locked position when one of the at least two abutments cooperates with one of the at least two flanges; the assembly is in the unlocked position when the at least two abutments are not aligned with respect to the at least two flanges.
 25. The assembly of claim 22, further comprising a keying feature that prevents the assembly from moving into the locked position when the upper portion and the lower portion are not aligned in a correct orientation, wherein the keying feature comprises a first feature on the upper portion and a second feature on the lower portion.
 26. The assembly of claim 25, wherein: the first feature is a tab; the second feature comprises a ramp and a recess; and the tab is configured to slide along the ramp as the assembly moves from the unlocked position toward the locked position and wherein the tab is received in the recess when the assembly is in the correct orientation.
 27. The assembly of claim 25, wherein: the first feature is a plurality of slots; the second feature comprises a plurality of ribs; and the plurality of ribs are received within the plurality of slots when the assembly is in the correct orientation.
 28. The assembly of claim 22, wherein the flow channel narrows from the inlet toward the outlet.
 29. The assembly of claim 22, wherein the upper portion comprises a collar that is rotatable with respect to a top surface of the upper portion.
 30. An assembly for electrolytic purification comprising: (a) an upper portion comprising a plurality of chlorine-generating electrode plates and a top surface, wherein the top surface comprises a transparent portion; (b) a lower portion comprising an inlet and an outlet and a cavity, wherein an exterior of the lower portion is opaque; wherein the upper portion is separable from the lower portion and wherein, in an assembled position, the plurality of chlorine-generating electrode plates is disposed in the cavity of the opaque lower portion; and wherein the transparent portion of the top surface of the upper portion is arranged to allow visibility of an upper surface of the plurality of chlorine-generating electrode plates when the assembly is in the assembled position. 